PANDROL Alpha Grinder User manual

Alpha Grinder
OPERATION AND MAINTENANCE
MANUAL
ENG_OMM_AlphaGrinder_P01
10th July 2019

OPERATION AND MAINTENANCE MANUAL | ENG_OMM_AlphaGrinder_P01 | 10th July 2019
© Pandrol 2020
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Revision History
Version
Date
Author
Comments
P01 10-7-2019 New manual

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Contents
Preface
4
1.
Safety Information
5
1.1 General
5
1.2 Safety Actions
5
1.3 General Warnings
6
1.4 Specific Warnings
6
1.5 Qualified Personnel
7
2.
Warning Labels and Information Symbols
8
3.
Machine Components
9
3.1 Main Unit
9
3.2 Technical Specifications
10
3.3 Conformance EN13977 Gauge
11
3.4 Controls
12
4.
Installation and Use
13
4.1 Installing grindstone
13
4.2 Installing on rail
13
4.3 Adjustments
13
4.4 Start the motor/machine
13
4.5 Operation Grinding
13
4.6 Remove grinder from track
14
5.
Transporting and Parking
15
5.1 Preparing for Transport or Storage
15
6.
Maintenance
17
6.1 General
17
6.2 Maintenance Schedule
18
6.3 Grease Points
19
7.
Mounting Torque for Screws & Nuts
20
8.
Warranty and Service
21
8.1 Warranty
21
8.2 Service
21
8.3 Contact
21
9.
Declaration of conformity
22

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Preface
Thank you for choosing Alpha Grinder! You are now the owner of a quality
product from Pandrol.
This manual aims to help you get to know your new Alpha Grinder, to use it in the best way and to maintain it
properly for a long lifetime. It also presents important safety regulations and warnings.
The manual is intended for people who handle and operate Alpha Grinder. It is originally written in Swedish and
then translated into the local language by Pandrol AB.
Pandrol AB reserves the right to change specifications, equipment, instructions and maintenance guidelines
without prior notice.
The manual contains instructions about the following topics:
1. Installation
2. Operation
3. Safety features and warnings
4. Maintenance and troubleshooting
IMPORTANT
This manual contains ordered actions, e.g.
1. Do this
2. …and then this…
3. …and finally this
These actions must be done in the numerical order presented.

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1. Safety Information
1.1 General
The machine is designed to grind the railhead.
Warnings and safety precautions described in this document shall only be considered as a minimum. National
conditions, standards and regulations override conditions, standards and regulations described in this document.
Work with the machine is only to be carried out by qualified personnel, well-informed and educated in general
railway workmanship and specifically in the conditions, standards and regulations on specific rail track.
The machine may only be used for its specified purpose.
Any adjustments or service on the machine is only allowed to be done by qualified personnel that have read and
understood this manual and have had training and information from Pandrol AB.
1.2 Safety Actions
Read and understand all safety regulations and warnings before installation, operating or performing maintenance
on this machine.
Locate stop buttons, emergency stop buttons and keys before installation, operating or performing grinding with
this machine. The emergency stop button is not allowed to be used to stop the machine normally.
The machine is never to be used as a transport vehicle for personnel or equipment.
Be sure that unqualified persons are not in the operating area during installation, use or maintenance.
Safety regulations regarding personnel in operating area for the Alpha Grinder are valid for this machine.
Use standards and regulations, accident prevention regulations and regulations concerning special ambient
conditions (e.g. areas potentially endangered by explosive materials, heavy pollution or corrosive influences).
It is of great importance that all service, component replacements or other operations in the electronic or motor are
accomplished by qualified personnel only.
The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards. The
manufacturers of the solvents and lubricants should be contacted for safety data. The recommended precautions
and procedures of the manufacturers should be followed.
The use of an air jet, which must be less than 8 bar, to blow parts clean or to blow them dry after being cleaned
with a solvent will cause particles of dirt and/or droplets of the cleaning solvent to be airborne. These conditions
may cause skin and/or eye irritation.
When using an air jet do not direct it toward another person. Improper use of air jet could result in bodily injury.
The machine is not allowed to be used on a track that is open for traffic.
Caution shall be exercised when the operator leaves the Alpha Grinder especially when adjacent track is trafficked
and can endanger the safety.
Personal eye protection must be worn when undertaking work.
Personal ear protection must be worn when undertaking work.
All personnel except for the operator are to be kept at least 3 m from machine when working.

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Operators and service personnel should wear appropriate protective equipment, such as gloves, goggles and
overalls.
Alpha Grinder is only to be used by trained personnel, thoroughly familiar with and trained in general railway
workmanship.
The equipment should be operated according to the conditions and standard regulations applying to the track they
are working on.
1.2.1 Safety Equipment
The machine is to be equipped with safety equipment according to national requirements.
1.3 General Warnings
Incorrect installation, maintenance and/or operation of this equipment may be dangerous and may result in severe
personal injuries.
1.4 Specific Warnings
1.4.1 Moving Parts
When operated, some parts of the Alpha Grinder are moving. Moving parts can cause personal injury. To avoid
accidents, follow the guidelines below:
•Keep hands etc. away from moving parts when operating the machine
•Make sure no unauthorized personnel are in the working area when working the machine
1.4.2 Live Current
Contact with electric parts can damage the equipment if live current is present. To avoid accidents, follow the
guidelines below:
•If electricity needs to be connected for testing purposes: keep hands, tools etc. away from all electrical parts.
In any other case:
1. Shut off the vehicle engine
WARNING
Moving parts - risk of crushing
WARNING
Live current - risk for damage on equipment and/or people

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1.4.3 Machine in Operation
Special precautions must be taken to ensure that operation of the machine will not result in severe injury and/or
damage to the equipment or personnel.
To avoid accidents, make sure no one is in the vicinity of the machine before operation is started.
1.4.4 Operator Leaves the Machine Unattended
When the operator leaves the machine unattended, the machine must always be parked horizontally on the
ground.
1.5 Qualified Personnel
The Alpha Grinder is only to be used by trained personnel, thoroughly familiar with and trained in general railway
workmanship. The equipment should be operated according to the conditions and standard regulations applying to
the track they are working on.
The equipment must be serviced, maintained, or in any way modified only by trained personnel, who are familiar
with the Operation & Maintenance Manual and have received training and information from Pandrol AB.
In order to avoid personal injury and/or material damage, everyone involved with assembling, starting-up or
overhaul must possess relevant knowledge of the following
•The automation technology sector
•Dealing with dangerous voltages
•Using standards and regulations, accident prevention regulations and regulations concerning special ambient
conditions (e.g. areas potentially endangered by explosive materials, heavy pollution or corrosive influences)..
WARNING
Touching parts that are subject to high voltage may cause grave damage to health
All maintenance and service on the electric system is to be carried out by qualified personnel

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2. Warning Labels and Information Symbols
Below are examples of warning labels and information symbols on the machine. If any of these labels become
damaged or lost, they are to be replaced with new original warning labels that are available from Pandrol AB.
Figure
1: Warning Labels and Information Symbols

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3. Machine Components
3.1 Main Unit
The Main Unit is the heart of Alpha Grinder. It contains the engine and components. The handlebar with the
operator controls is also mounted on the Main Unit.
Figure
2: Components
Table 1:
Item
Description
1 Lifting handles - support legs
2 Height adjustment - grindstone
3 Controls
4 Lifting eye
5 Motor
6 Lifting handles - support legs
7 Working lights
8 Grindstone
9 Angle adjustment - grindstone
10 Support roller unit

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3.2 Technical Specifications
Table 2:
Alpha Grinder
Measurements
Measures
Weight 105 kg
Grindstone Diameter, outside 150 mm
Diameter, inside
Height
Running speed 4000 rpm
Min/Max angle of operation
Engine
Manufacturer Honda
Model GX 270
Type Air cooled 4-stroke OHV petrol engine. 25 inclined
cylinder, horizontal shaft. Cast iron sleeve
Power 5,1 kW 3600 Rpm
Fuel Automotive gasoline (unleaded)
Fuel tank capacity 5,3 litre
Electronics Voltage 12 volt DC
Ground Negative
Noise data Noise level, idle running measured on all four sides, 1 meter 93,2 dB
Noise level, full speed measured on all four sides, 1 meter 95,8 dB
Vibration data Grinding Front right handle 8,94 m/s²
Grinding Rear handle (adjustment wheel) 4,18 m/s²

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3.3 Conformance EN13977 Gauge
Figure
3:

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3.4 Controls
The Alpha Grinder is operated by the operator, Fig.4, Fig 5.
Figure
4:
Figure
5:
Table 3:
Item
Description
1
Emergency stop button
2
Light switch
3
Grindstone angle
4
Start cord
WARNING
Do not operate the machine before performing the setup procedure.

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4. Installation and Use
4.1 Installing grindstone
The engine must be switched off when mounting/dismounting the grindstone or when the machine is resting on
the ground.
Dismounting grindstone
1. Place the grinding machine stable and suitable for replacing the grindstone.
2. Remove the cover around the grindstone, 3 screws M8 M6S
3. Lock axle with key size 24
4. Unscrew the adapter for the grindstone with key size 24 from the axle.
5. Release the adapter from the grindstone and replace/fit the new.
Mounting the grindstone
Follow the description above in reverse order.
4.2 Installing on rail
The engine has to be switched off when mounting/dismounting the machine or when the machine is
resting on the ground.
Inspect the Alpha grinder to make sure there are no damages and that it is completely free from defects.
4.3 Adjustments
Check rail width, allowed play 5-15 mm.
Check the play between rail and grindstone, clearance has to be at least 1 mm. Adjust with wheel/knob.
4.4 Start the motor/machine
Make sure all safety information have been read before starting the machine.
Ensure all pre checks have been conducted. The machine must only be started on the track.
2. Start with the machine in the flat position and with the grindstone in the horizontal position.
3. Check the clearance between the grindstone and the rail. The grindstone must be clear from the weld.
4. Check that the protection cover is in place and is folded down.
5. Check that the emergency stop is extended.
6. Start the engine by holding the grip and pulling the start cord until motor starts, allow the cord to retract.
4.5 Operation Grinding
Make sure all safety information have been read before using the machine.
7. Set the grinder to max.
8. Gently lower the grindstone over the grinding point on the rail. until it fires fire from the grinding point.

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9. Move the grinder back and forth over the grinding point/weld, lowering the wheel until the weld is 1 mm above
the rail head.
10. Repeat the procedure until it is flat.
11. Rotate the machine sideways to grind the side of the rail until the weld is 1 mm above the rail head. The angle
adjustment makes it possible to work on both sides of the rail without turning the machine around.
4.6 Remove grinder from track
Lift the machine off the rail and park it with the handles folded down. Release arm and place on machine in
transport position.
DO NOT lift the Alpha Grinder manually.
Make sure the machine is lifted in lifting eye. Use a lifting device suitable for the purpose.
F
igure 6:

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5. Transporting and Parking
5.1 Preparing for Transport or Storage
Place the Alpha Grinder on a flat surface. It must stand straight up. Use straps to fasten and secure.
DO NOT lift the Alpha Grinder manually.
Figure
7:
Figure
8:

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WARNING
The Alpha Grinder must only be operated by trained personnel and with experienced
workmanship.
All safety precautions and other requirements is the responsibility of the equipment
operator.
Operation or preparation for use can be dangerous and may cause serious personal
injuries if not correctly performed. All safety and necessary precautions shall be taken by
the operator of the machine. The machine operator is also responsible that nobody
interferes with the Alpha Grinder whilst in use and powered.

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6. Maintenance
6.1 General
Maintenance and overhaul is to be carried out by qualified personnel only.
The Alpha Grinder is designed for the absolute minimum of maintenance. All its components have been chosen for
a long working-life and high quality.
The Alpha Grinder requires:
•A minor maintenance before and after every working shift
•A lubrication every 40 hours or once a week
•A more comprehensive overhaul after 500 hours or once a year
Warranty is based on parts and spares delivered by Pandrol AB.
WARNING
All adjustments work, overhaul and service must take place with the engine turned off, cooled
down and with grinding stone disengaged. Failure to do so could lead to fatal injury.
It is of great importance that qualified personnel accomplish all service and overhaul

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6.2 Maintenance Schedule
Table 4:
Item Servicing Action
Frequency
Each time
used
Once a week or
every 40 hours
Once every 6
months or 250
hours
Once a year or
every 500
hours
Entire unit Check for oil leakage X
Screws and nuts Check/tighten if
needed
X
Grindstone Check/replace if
damaged
X
Grease points
on grinder
Lubricate with grease
SKF LEGP 2 or
equivalent
X
Roller surface
on slide bar
Clean and lubricate
with oil spray*
X
Bolts Lubricate with oil
spray*
X
Engine See Honda manual X X X X
Warning labels Replace worn and
replace missing
labels
X
*) CRC5-56 or similar
**) Let the machine rest at least on hour before checking level
***) Recommended hydraulic oil:
At temperatures below 25 °C is oil of viscosity grade 46 recommended
At temperatures above 25 °C is oil of viscosity grade 68 recommended
It is very important that the service intervals are thoroughly followed to guarantee the safety and the performance
of the machine

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6.3 Grease Points
Figure
9:
Figure
10:
Figure
11:

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7. Mounting Torque for Screws & Nuts
The preload force must be maintained at a level where the tensile stress and the intensity of the torsional stress do
not exceed the screws yield stress for the specific material. Its main function is to clamp together the assembled
parts and produce friction force between the assembled parts.
At Pandrol AB we mainly use steel screws and nuts. The table below shows the nominal tightening torque in Nm
for the screws and nuts that are used
These torques do not apply to wheel bearings!
Table 5:
Thread diameter
[mm]
Tightening Torque (per bolt grade) [Nm]
Grade 8.8 Grade 10.9 Grade 12.9
5 5,7 8,1 9,7
6 9,8 14 17
8 24 33 40
10 47 65 79
12 81 114 136
14 128 181 217
16 197 277 333
18 275 386 463
20 385 541 649
22 518 728 874
24 665 935 1120
27 961 1350 1620
30 1310 1840 2210
33 1770 2480 2980
36 2280 3210 3850
IMPORTANT
Check that all bolts and nuts are tightened at least every 8 hours until 80 hours have been
reached. If necessary, use spanner to tighten.